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Method for forming a composite support beam

Method for forming a composite support beam description/claims

1) Technical Field

Embodiments of the disclosure relate to methods for forming support beams and, more specifically, to methods of forming composite J-beams.

2) Description of Related Art

One part that is widely used by aircraft and other structures is a support beam. One type of support beam is a J-beam, which is used for cargo floor beams, wing spars, and various other structures. Composite materials are often selected to form support beams, such as J-beams, since composite materials may be a lighter alternative to metals while still maintaining sufficient strength. Composite J-beams may be formed from an assemblage of “C” and “Z” channels. Typically, composite “C” channels are formed, among other ways, with an elastomeric membrane hot forming machine. Composite “Z” channels are usually fabricated by hand lay up of a resin-impregnated fibrous material on a “Z” channel tool.

The drive for increased speed and efficiency and a desire to reduce fabrication costs have led manufacturers of J-beams to seek manufacturing methods to form beams in a short amount of time and at a low cost. Prior and emerging art have provided limited capabilities to satisfy these requirements. When using composite material, one difficult challenge in forming a J-beam is the forming operation of the “Z” channel. The fabrication of the “Z” channel is largely performed by hand. Unfortunately, the current method of fabrication of the “Z” channel is labor intensive. As such, the speed of production is slow, and the efficiency is low. The labor intensive fabrication process drives up production costs.

Thus, there exists a need for a more efficient method of forming a composite support beams, including composite J-beams. It would be advantageous to have a fabrication process based upon more automation and less labor. In addition, it would be advantageous to provide methods to increase the production rate while making the process cost effective.

Embodiments of the disclosure may address the above needs and achieve other advantages by providing methods for fabricating support beams, such as J-beams. Generally, embodiments of the disclosure provide methods for fabricating support beams with greater efficiency by way of more automation than conventional approaches. In one embodiment, for example, support beams may be formed by bending a charge to create either one or two “Z” channels while the charge is in contact with either one or two “C” channels.

In one embodiment, a method of creating a support beam from a C-shaped charge and an additional charge is provided. The method includes supporting a C-shaped composite charge on a first forming tool and placing an additional composite charge on at least a portion of the C-shaped composite charge. The method further includes placing a second forming tool proximate the first forming tool and positioning a fixed forming tool proximate a first portion of the additional composite charge with the additional composite charge extending thereacross. The method may include heating the first forming tool, the fixed forming tool, or both prior to formation of the support beam. Additionally, the method includes bending a second portion of the additional composite charge about the fixed forming tool into a bent configuration resulting in the formation of a support beam, such as a J-beam. The bending of a second portion of the additional charge may include inflating at least one bladder proximate the first forming tool. The method may include curing the support beam once the second portion of the additional composite charge is bent. The method may include bending a third portion of the additional composite charge about the first forming tool. The method may also include bending the second and third portions of the additional composite charge concurrently.

An additional embodiment provides a method for forming a pair of support beams, such as J-beams. The method includes supporting first and second C-shaped composite charges upon first and second forming tools, respectively. The first and second forming tools may be heated to enhance forming operations. The method further includes placing an additional charge upon at least portions of the first and second charges and a third forming tool positioned between the first and second forming tools. In addition, the method includes positioning a fixed forming tool proximate an intermediate portion of the additional charge that extends between the first and second charges. The method may include making a release cut in the additional charge prior to positioning the fixed forming tool. The method includes moving the first and second forming tools relative to the fixed forming tool in order to bend portions of the additional charge that are proximate the first and second forming tools into a bent configuration relative to the intermediate portion of the additional charge. For example, the inflation of at least one bladder proximate each of the first and second forming tools can move the first and second forming tools relative to the fixed forming tool. In order to enhance formation operations, a vacuum bag may be inflated that encloses the first, second, and fixed forming tools, the first, second, and additional charges, and each bladder. Alternatively, the activation of mechanical actuators that are operably connected to the first and second forming tools, respectively, can move the first and second forming tools relative to the fixed forming tool. The method may include curing the support beams once the first and second forming tools are moved. In addition, the method may include bending a first end portion and second end portion of the additional charge about the first and second forming tools, respectively. The method includes separating the pair of support beams by dividing the intermediate portion of the additional charge.

Another embodiment provides a method for forming a pair of support beams, such as J-beams. The method includes supporting first and second C-shaped composite charges upon first and second forming tools, respectively. The method further includes placing an additional charge upon at least portions of the first and second charges and a third forming tool positioned between the first and second forming tools. In addition, the method includes positioning a fourth forming tool proximate the first forming tool and a fifth forming tool proximate the second forming tool. The third forming tool can be heated to enhance formation operations. The method may also include cutting in two the additional charge before moving the third forming tool. The method includes moving the third forming tool toward the additional charge to bend portions of the additional charge and thereby form the pair of support beams. In addition, the method may include curing the support beams after the third forming tool is moved. The method may include bending a first end portion and a second end portion of the additional charge about the first and second forming tools, respectively.

Having thus described the embodiments of the disclosure in general terms, reference will now be made to the accompanying illustrations, which are not necessarily drawn to scale, and wherein:

FIG. 1 is a perspective illustration of a J-beam.

FIG. 2 is a section illustration of part of the forming apparatus with two C-shaped composite charges according to one embodiment.

FIG. 3 is a section illustration of part of the forming apparatus with two C-shaped composite charges according to one embodiment.

FIG. 4 is a section illustration of part of the forming apparatus with two C-shaped charges and one additional composite charge according to one embodiment.

FIG. 5 is a section illustration of part of the forming apparatus with two C-shaped and one additional composite charge according to one embodiment.

FIG. 6 is a section illustration of the forming apparatus with two C-shaped and one additional composite charge according to one embodiment.

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